WO1997000622A1

WO1997000622A1 - Restructured meat products and method of preparing same

Info

Publication number: WO1997000622A1
Application number: PCT/US1995/008940
Authority: WO
Inventors: Leonard Yaiko
Original assignee: Griffith Laboratories Worldwide, Inc.
Priority date: 1994-04-05
Filing date: 1995-06-23
Publication date: 1997-01-09

Abstract

Restructured meat products made by cutting meat parts into silice and tumbling with salt and optionally with phosphate, water and other ingredients to form a tumbled meat mass that is shaped into a restructured meat product having the desired shape and thickness in a forming machine or by stuffing the tumbled meat mass into a casing and heating to set the protein in the meat mass.

Description

RESTRUCTURED MEAT PRODUCTS AND METHOD OF PREPARING SAME

BACKGROUND OF THE INVENTION

This invention relates generally to restructured meat products and to methods of making such restructured meat products. More particularly, this invention relates to restructured meat products having texture, taste and appearance on a par with whole-muscle meat cuts.

A variety of different restructured meat products are available in the marketplace, particularly in the fast food industry. Demand for such products arises out of the need for meat products having uniform appearance, shape and size which otherwise exhibit the texture, taste and appearance of whole-muscle meat cuts. It arises as well out of environmental and economic considerations which drive efforts to use meat cuts which ordinarily must be discarded or ground for use, usually as ingredients in hamburger or sausage.

Unfortunately, presently available restructured meat products are readily distinguishable from whole- muscle meat cuts, since they lack one or more of the texture, taste and appearance of such whole-muscle meat cuts. This is primarily because current methods for producing restructured meat products damage or destroy the meat fibers in the course of restructuring. Once these fibers are destroyed, it is no longer possible to achieve the desired end product. Finally, current methods for producing restructured meat products are complex, labor-intensive and expensive. For example, many such methods require ten or more production steps. Restructured meat products would be more economical and therefore more popular if simpler, less time-consuming and less labor-intensive methods for producing them could be developed. SUMMARY In accordance with the present invention, a meat part is cut into thin slices which retain the fibrillar structure of the meat. These slices are formed into a tumbled mass in a tumbler to which a treatment composition is added. The treatment composition contains salt and, optionally, water, phosphate, flavorings, and dextrose.

The tumbling is continued long enough to achieve partial protein extraction from the tumbled mass while enhancing moisture absorption and retaining the original fibrillar structure. Once the tumbling step is completed, the tumbled mass is placed in a forming machine to fashion the desired shapes and thicknesses of the final restructured meat cuts. These meat cuts are then frozen and packaged for storage or distribution and use.

In an alternate embodiment, the tumbled mass is stuffed into a waterproof casing or bag which is sealed and cooked sufficiently to set the protein and render the product salmonella-safe. The product is then chilled and provided to a final user in either refrigerated or frozen form. The user will remove the product from the casing or bag and cook it to the final desired temperature in either an oven or on a rotisserie to produce a roast-form product ready for eating.

DETAILED DESCRIPTION The Meat Parts

The present invention may use as the meat part any part of the carcass of animals providing meat in which the natural juices of the meat have adhesive binding properties due to the presence of binding proteins, particularly myofibrillar proteins, such as myosin, actin, and actomyosin. Typical such meats include beef, pork, veal, lamb, turkey, chicken, as well as other fowl and wild animal meats like venison. Among these meats, beef, pork and turkey are preferred. Also, combinations of two or more of the above meats may be used. Slicing

The meat parts are cut into thin slices which retain the fibrillar structure of the meat. The slices should have thicknesses of about 1.6 - 5.0mm, and preferably about 1.6mm. The major surface area of these slices will vary depending on the meat types and parts from which they are cut, as well as the direction in which the cuts are done. Generally, the slices should have a major surface area as large as the particular meat part will permit, and in no event should the slices have a major surface area of less than 5 sq. cm. Treatment Solution and Tumbling Step The meat slices are placed in a tumbler to which a treatment composition is added. It is preferred that a vacuum tumbler be used and the vacuum pulled preferably should be in the range of about 500-750mm Hg. It is also preferred that the temperature in the tumbler be maintained at a temperature of about -1.5 to 10°C and more preferably at a temperature of about -1 to 2°C.

The treatment composition must include enough salt to provide from about 0.1 to 2% by weight of salt based on the weight of the meat being treated. Preferably about 0.75% by weight salt will be provided. The preferred salt is NaCl, although KCl could be used, either alone or in combination with NaCl .

Preferably, the treatment composition also includes a salt or combination of salts of phosphoric acid, which will be referred to collectively as "phosphate" . The preferred phosphate is sodium tripolyphosphate ("STPP") . The level of phosphate should be in the range of about 0 - 1.0% by weight, based on the weight of the meat being treated. Preferably, about 0.5% by weight phosphate will be present. The treatment composition may optionally also contain any appropriate meat flavoring. It may also optionally include dextrose in order to improve the browning of the final product. The level of dextrose should be from about 0 to 2% by weight and preferably about 0.75% by weight, based on the weight of the meat being treated.

While it is preferred that the treatment composition include added water and that the other ingredients of the composition be dissolved in the added water, it is possible to use the ingredients in a dry form and rely on the meat juices to act as a solubilizing agent. Thus, the added water should lie in the range of about 0 - 25% by weight, based on the weight of the meat being treated. Preferably, about 15% by weight water will be added.

Since it is preferred in order to obtain the optimal mouthfeel in the end product that the fat level of the parts before tumbling be in the range of about 5 - 30% by weight and preferably about 15 - 20% by weight, where the meat parts do not have enough inherent fat, fat may be added. Although it is preferred that added fat come from the same species as the meat part, where permitted by applicable law, any fat having or mimicking the organoleptic properties of meat fat can be used, whether from a meat or a vegetable source.

Tumbling will continue long enough to take up all of the available moisture and to achieve coherence between the meat slices without overbinding. It has been found that if the meat is tumbled too long, the product becomes tough and rubbery, and takes on a non-fiberous texture. Tumbling for too short a period produces insufficient binding and results in an end-product lacking the desired coherence of whole muscle meat cuts. Tumbling for a proper period achieves partial protein extraction and at the same time enhances moisture absorption and retains the original fibrillar structure within the meat. Shaping

The tumbled meat mass is placed into a forming machine and the desired shapes and thicknesses of the meat cuts are stamped out. For example, a round shape could be stamped to fit a sandwich bun. These portions are then frozen and packaged for storage or distribution and use.

In an alternative embodiment of the invention, the tumbled mass is stuffed into a waterproof casing or bag which is sealed and cooked sufficiently to set the protein and render the product salmonella-safe. Typically, the casing or bag is of a size and shape which simulates a roast and the cooking step is carried out in a water bath heated to the temperature desired in the final meat product. For example, the first cooking step could use a water bath at about 60°C to heat the meat to that temperature which would be maintained for at least about 15 minutes to destroy salmonella bacteria. Then, the product could be quick-chilled to about 5°C and shipped to a final user in refrigerated form or quick- frozen and shipped in frozen form. The user will remove the product from the casing or bag and cook it to the final desired temperature in either an oven or on a rotisserie to produce a roast-form product ready for eating. Of course, if the product is shipped in frozen form, it typically will be warmed in a cooler to temper it out before removal from the casing or bag prior to the second or final cooking step.

The following examples are intended to be illustrative of the invention and to teach one of ordinary skill in the art how to make and use the invention. These examples are not intended to limit the invention or its protection in any way. EXAMPLES

1. In this example, a restructured meat product was prepared from a 9.1 kg choice grade inside round with surface fat removed. The inside round was cut in half and placed in a freezer at about -35°C for about 1 hour in order to firm the exterior and facilitate slicing. The meat temperature after 1 hour in the freezer was about -4 to -1°C.

The chilled halves of the inside round were sliced on a Berkel slicer (Model 808) on a number 5 setting to produce 3.2mm thick slices. The dimensions of the initial center slices were about 15.2cm x 30.5cm.

A treatment solution was prepared from the following ingredients: Ingredient Percentage By Weight

NaCl 4.5

Dextrose 4.5

Blend of Sodium Tripoly¬ phosphate & Sodium Pyro¬ phosphate 1.4

Flavoring 1.8

Water 87.8

387 grams of the treatment solution were placed into a Vortron vacuum tumbler (20kg capacity) along with 2270 grams of the sliced beef. 711mm of vacuum were pulled and the mixture tumbled for about 30 minutes.

The resulting meat mass was then removed from the tumbler and placed in a Hollymatic Model 54 food portioning machine. Patties having a 1.9cm thickness, an 8.9cm diameter, a weight of about 114g and a fat content of about 10% by weight were formed. These patties were quick-frozen in a -35°C blast freezer and packaged.

The frozen patties were subsequently broiled using a conventional broiling procedure. The patties were nearly identical to whole-muscle cuts in texture, taste and appearance.

Alternatively, the resulting meat mass referred to above could be placed in a waterproof, shrink type casing, sealed by conventional means, and cooked to raise its temperature to 60°C and maintained at that temperature for about 15 minutes to make the product salmonella-safe. The product would then be either quick- chilled to about 5°C and held at that temperature or frozen in a -35°C blast freezer. The chilled or frozen encased product could later be cooked on a rotissierie or in a conventional oven to provide a meat portion nearly identical to whole-muscle meats in texture, taste and appearance. 2. In this example, a restructured meat product was prepared from an 11.4kg choice grade chuck roll. The fully frozen chuck roll was removed from the freezer and tempered 24 hours to a temperature of -1.0°C. The tempered chuck roll was sliced on a Berkel slicer (Model 808) on a number 7 setting to produce 1.6mm thick slices. A treatment solution was prepared from the following ingredients:

Ingredient Percentage bv Weight

NaCl 5.0 Dextrose 5.0

Phosphate Blend 3.3

(STPP & Sodium Pyrophosphate) Flavoring 2.7

Water 84.0

681 grams of the treatment solution were placed into a Vortron vacuum tumbler (20kg capacity) along with 4540 grams of the sliced beef. 711mm of vacuum was pulled and the mixture tumbled for about 40 minutes.

The resulting meat mass was then removed from the tumbler and placed in a Hollymatic Model 54 food portioning machine. Patties having a 1.9cm thickness, an 8.9cm diameter and a weight of about 114g were formed. The fat content of these uncooked patties was approximately 20% by weight. These patties were quick- frozen in a -35°C blast freezer and packaged.

The frozen patties were subsequently broiled using a conventional broiling procedure. The patties were nearly identical to whole-muscle cuts in texture, taste and appearance. While the present invention is described above in connection with a preferred or illustrative embodiment, this embodiment is not intended to be exhaustive or limiting of the invention. Rather, the invention is intended to cover all alternatives, modifications and equivalents which may be included within its spirit and scope, as defined by the appended claims.

Claims

WHAT IS CLAIMED IS:

1. A process for preparing a restructured meat product from meat parts comprising: cutting the meat parts into slices; tumbling the meat slices with a treatment composition including salt to achieve coherence between the meat slices and to form a tumbled meat mass; shaping the tumbled meat mass into a restructured meat product having the desired shape and thickness.

2. The process of claim 1 in which the meat part is chosen from the group consisting of beef, pork, veal, lamb, turkey, chicken or venison.

3. The process of claim 1 in which the meat part is beef.

4. The process of claim 1 in which the meat part is turkey.

5. The process of claim 1 in which the slices are about 1.6 - 5.0mm in thickness.

6. The process of claim 1 in which the slices are about 1.6mm in thickness.

7. The process of claim 1 in which the slices have a major surface area of no less than 5 sq. cm.

8. The process of claim 1 in which the salt is NaCl.

9. The process of claim 1 in which the salt includes KCl.

10. The process of claim 1 in which the treatment composition includes enough salt to provide from about 0.1 - 2% by weight salt based on the weight of the meat part.

11. The process of claim 1 including enough salt to provide about 0.75% by weight salt based on the weight of the meat part.

12. The process of claim 1 including enough phosphate to provide about 0 - 1% by weight phosphate.

13. The process of claim 1 including enough phosphate to provide about 0.5% by weight phosphate.

14. The process of claim 1 in which the phosphate includes sodium tripolyphosphate.

15. The process of claim 1 in which the composition includes meat flavoring.

16. The process of claim 1 in which the treatment composition includes enough dextrose to provide about 0 - 2% by weight based on the weight of the meat part.

17. The process of claim 1 in which the treatment composition includes enough dextrose to provide about 0.75% by weight based on the weight of the meat part.

18. The process of claim 1 in which the treatment composition includes sufficient added water to provide about 0 - 25% by weight water, based on the weight of the meat part.

19. The process of claim 1 in which the treatment composition includes sufficient added water to provide about 15% by weight water, based on the weight of the meat part.

20. The process of claim 1 in which sufficient fat is provided to produce a fat level in the end product of about 5 - 30% by weight.

21. The process of claim 1 in which sufficient fat is provided to produce a fat level in the end product of about 15 - 20% by weight.

22. The process of claim 1 in which the tumbled meat mass is shaped by stuffing the meat mass into a waterproof casing, and sealing.

23. The process of claim 22 in which the stuffed casing is cooked sufficiently to set the protein in the meat mass.

24. A process for preparing a restructured meat product from meat parts comprising: cutting the meat parts into slices about 1.6 - 5.0mm in thickness; tumbling the meat slices under vacuum with a treatment composition including salt, phosphate and water to achieve coherence between the meat slices and form a tumbled meat mass; shaping the tumbled meat mass into a restructured meat product having the desired shape and thickness.

25. The process of claim 24 in which the treatment composition includes enough salt to provide from about 0.1 - 2% by weight salt based on the weight of the meat part.

26. The process of claim 24 in which the treatment composition includes enough salt to provide about 0.75% by weight salt based on the weight of the meat part.

27. A process for preparing a restructured meat product from meat parts comprising: cutting the meat parts into slices; tumbling the meat slices with a treatment composition including salt to achieve coherence between the meat slices and to form a tumbled meat mass; stuffing the tumbled meat mass into a casing and sealing; and cooking the stuffed casing sufficiently to set the protein in the meat mass.

28. A restructured meat product having a desired shape and thickness, prepared from meat parts by the process comprising: cutting meat parts into slices; tumbling the slices with a treatment composition including salt to achieve coherence between the meat slices and to form a tumbled meat mass; shaping the tumbled meat mass into the restructured meat product.

29. A roast-form restructured meat product prepared from meat parts by the process comprising: cutting meat parts into slices; tumbling the slices with a treatment composition including salt to achieve coherence between the meat slices and to form a tumbled meat mass; stuffing the tumbled meat mass into a casing and sealing; and cooking the stuffed casing sufficiently to set the protein in the meat mass.

30. The roast-form restructured meat product of claim 29 in which the casing is removed from the meat mass after cooking to set the protein and the meat mass is cooked to a final desired temperature to produce a roast-form product ready for eating.